This application claims the benefit of U.S. Provisional Patent Application No. 63/398,411, filed on August 16, 2022 and entitled PASSENGER SEAT HEADREST WITH ADJUSTABLE HINGE.

The field of the invention relates to passenger seats for passenger vehicles such as aircraft, and more particularly to headrests for passenger seats.

Passenger seats, such as those provided on aircraft, trains, vehicles, and the like, often include components that are hinged together. As an example, a headrest for a passenger seat may include a center portion and wings, and the wings are attached to the center portion via a hinge such that the wings are movable relative to the center portion. Traditional headrests and hinges on such headrests do not allow for any adjustments to be made to the hinges. In such cases, when the hinge connecting the wing to the center portion is loose or worn out over time, the headrest must be disassembled such that the old hinge is replaced with a new hinge.

Document CN208393194U describes a multidirectional adjustable car seat headrest comprising a main portion, a wing; and a hinge connecting the wing with the main portion such that the wing is movable relative to the main portion about at least one axis, wherein the hinge is adjustable such that a resistance to rotation of the wing relative to the main portion is adjustable.

Document US2018/105087A1 describes an adjustable headrest including a guide configured to be coupled to a seat, a head support coupled to the guide and configured to be movable along an adjustment path relative to the seat, and a slider having a surface defining a recess receiving the guide such that the surface of the slider contacts a surface of the guide.

Document FR2990658A1 describes a hinge having two sides that are connected by a folding zone, which is formed in the shape of open slot coupling, wherein the hinge is able to adopt an open assembly configuration in which the sides are isolated from one another, and a set of tightened configurations in which the sides are brought closer to each other.

Document JPS57158128 describes a headrest comprising side supports including vertical disc-like frames, an arm which supports said frames at its ends, and stopper plates fixed to said arm in its middle. The arm, acting as an axis of rotation when the side supports are rotated forward relative to the main body of the headrest, is equipped with bending flat parts at its both ends which are fixed to the internal faces of the frames.

Document WO2009/020439A1 describes a head support unit comprising a mechanism formed by the assembly of two side support pieces to a central piece via a centerline shaft, a spring, a union nut, a shim and a spring washer.

Document CN110001488A describes a six-way headrest skeleton structure comprising a headrest front-rear adjustment mechanism and a headrest side wing rotating adjustment mechanism. The side wing adjustment mechanism comprises a base fixed to the headrest, supporting brackets symmetrically arranged on the two sides of the base, and side wing sheet metal plates vertically arranged on the supporting brackets. The side wing brackets are rotatably arranged on the side wing sheet metal plates in a stepless adjustment mode.

The terms "invention," "the invention," "this invention" and "the present invention" used in this patent are intended to refer broadly to all the subject matter of this patent and the patent claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below. Embodiments of the invention covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various aspects of the invention and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all drawings and each claim.

According to the present invention, a passenger seat headrest for a passenger seat includes a main portion, a wing, and a hinge connecting the wing with the main portion such that the wing is movable relative to the main portion about at least one axis. The hinge is adjustable such that a resistance to rotation of the wing relative to the main portion is adjustable.

The hinge includes a first hinge piece, a second hinge piece, and an adjuster connecting the first hinge piece with the second hinge piece. The adjuster defines a pivot axis for the hinge as the at least one axis, and the first hinge piece is movable relative to the second hinge piece about the pivot axis.

The first hinge piece includes a connecting portion, and the second hinge piece includes a first ear overlapping a first end of the connecting portion and a second ear overlapping a second end of the connecting portion.

The adjuster extends through the first ear and the connecting portion.

The adjuster includes a body and a head, the body extends through the first ear and the second portion, and the first ear is on the body of the adjuster between the connecting portion of the first hinge piece and the head of the adjuster.

The passenger seat headrest may include a first spacer between the first ear and the first end of the connecting portion, and a second spacer between the second ear and the second end of the connecting portion. The adjuster may extend through the first spacer and the second spacer.

In certain embodiments, the first hinge piece is connected to the main portion and the second hinge piece is connected to the wing, or the first hinge piece is connected to the wing and the second hinge piece is connected to the main portion.

The hinge may be adjustable between a tightened configuration and a loosened configuration.

The adjuster extends outwards from the hinge along the at least one axis.

The adjuster extends outwards in a downwards direction from the hinge.

The passenger seat headrest includes a dress cover covering the main portion and the wing, and the hinge may be adjustable without removing the dress cover from the main portion and the wing.

In certain embodiments, the hinge optionally includes a rotation limiter.

Various implementations described herein may include additional systems, methods, features, and advantages, which cannot necessarily be expressly disclosed herein but will be apparent to one of ordinary skill in the art upon examination of the following detailed description and accompanying drawings.

The specification makes reference to the following appended figures, in which use of like reference numerals in different figures is intended to illustrate like or analogous components.

• FIG. 1 is a perspective view of a passenger seat headrest for a passenger seat according to embodiments.
• FIG. 2 is a perspective view of the passenger seat headrest of FIG. 1 with a dress cover removed.
• FIG. 3 is a front view of the passenger seat headrest of FIG. 1 with the dress cover removed.
• FIG. 4 is a perspective view of a hinge of the passenger seat headrest of FIG. 1 according to embodiments.
• FIG. 5 is a front view of the hinge of FIG. 4.
• FIG. 6 is a perspective view of the hinge of FIG. 4 with rotation limiters removed.
• FIG. 7 is a front view of the hinge of FIG. 4 with rotation limiters removed.
• FIG. 8 is a perspective view of a first hinge portion and an adjuster of the hinge of FIG. 4.
• FIG. 9 is a perspective view of a second hinge portion and the adjuster of the hinge of FIG. 4.
• FIG. 10 illustrates the second hinge portion of the hinge of FIG. 4.

The subject matter of embodiments of the present invention is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described.

The described embodiments of the invention provide passenger seat headrests with adjustable hinges for passenger seats. While the passenger seat headrests are discussed for use with aircraft seats, they are by no means so limited. Rather, embodiments of the passenger seat headrests described herein may be used in passenger seats or other seats of any type or otherwise as desired.

FIGS. 1-3 illustrate an example of a passenger seat headrest 100 according to embodiments. The passenger seat headrest 100 may be generally supported on a passenger seat, such as but not limited to an aircraft passenger seat, using various techniques or mechanisms as desired. Referring to FIGS. 2 and 3, the passenger seat headrest 100 generally includes a main portion 102 and one or more wings 104. While two wings 104 are illustrated in FIGS. 2 and 3, the number of wings should not be considered limiting, and in other embodiments, the passenger seat headrest 100 may include a single wing 104 or a plurality of wings 104. The wings 104 may be pivotably attached to the main portion 102 (and/or to each other when a plurality of wings is provided on a side of the main portion 102) such that the wings 104 are movable relative to the main portion 102 about at least one axis. Cushioning may be supported on the main portion 102 and wings 104, and a dress cover 108 forming an outermost surface of the passenger seat headrest 100 (e.g., a surface that a passenger may contact her or his head) may be provided on the main portion 102 and wings 104.

In certain embodiments, a hinge 106 may pivotably connect each wing 104 with the main portion 102 and/or to each other. In some embodiments, a plurality of hinges 106 may connect each wing 104 with the main portion 102. Each hinge 106 may be connected to the wing 104 and the main portion 102 using various components or features as desired, including but not limited to mechanical fasteners 110. The number of mechanical fasteners 110 illustrated for each hinge 106 should not be considered limiting, and in other embodiments, devices and/or mechanisms other than mechanical fasteners may be utilized to connect the hinge 106 to each of the main portion 102 and the particular wing 104.

As best illustrated in FIGS. 4-10, each hinge 106 generally includes a first hinge portion 112 and a second hinge portion 114. An adjuster 116 connects the first hinge portion 112 with the second hinge portion 114 and defines a pivot axis 118 such that the first hinge portion 112 (and any component of the of the passenger seat headrest 100 attached thereto) may be positionable relative to the second hinge portion 114 (and any component of the passenger seat headrest 100 attached thereto) about the pivot axis 118. When assembled, the first hinge portion 112 may be connected to the main portion 102 or the particular wing 104, and the second hinge portion 114 may be connected to the other of the main portion 102 or the particular wing 104.

The first hinge portion 112 includes a connecting portion 120, and the second hinge portion 114 includes a first ear 122 and a second ear 124. The hinge includes an anchoring member 130 (see FIG. 10) for engaging the adjuster 116. In some embodiments, the anchoring member 130 may be provided within one of the ears of the second hinge portion 114, such as the first ear 122 as illustrated in FIG. 10. In other embodiments, the anchoring member 130 may be provided within the second ear 124 and/or within the connecting portion 120 of the first hinge portion 112. When assembled, the connecting portion 120 and the ears 122, 124 may be generally aligned along the pivot axis 118 such that the connecting portion 120 is between the ears 122, 124.

As best illustrated in FIGS. 8 and 9, the adjuster 116 includes a body 126 and a head 128. In certain embodiments, the body 126 of the adjuster extends through one of the ears 122, 124 and at least partially through the connecting portion 120. In embodiments where the anchoring member 130 is provided within the first ear 122, the body 126 may extend through the second ear 124, through the connecting portion 120, and into engagement with the anchoring member 130. Optionally, the body 126 may threadably engage the anchoring member 130 (e.g., via threading on the body 126 and/or the anchoring member 130, although other types of engagement may be utilized as desired. The adjuster 116 extending through the portions of the first hinge portion 112 and the second hinge portion 114 and into engagement with the anchoring member 130 may pivotably connect the hinge portions 112, 114. As discussed in detail below, the adjuster 116 may be adjusted to control and/or adjust a resistance to rotation between the first hinge portion 112 and the second hinge portion 114.

The head 128 of the adjuster 116 extends outwards from the second hinge portion 114, and when assembled, the first ear 122 (and/or the second ear 124) may be provided along the pivot axis 118 between the connecting portion 120 and the head 128. In some embodiments, and as illustrated in FIG. 3, the head 128 may extend outwards and downwardly from the hinge 106, although it need not in other examples. Optionally, the head 128 includes a stopper 132 for contacting the first ear 122 and/or the second ear 124 and limiting axial movement of the head 128. As discussed in detail below, the head 128 of the hinge 106 extending outwards from the hinge 106 allows for the adjuster 116 to be accessed without disassembling the entire passenger seat headrest 100.

Optionally, one or more first spacers 134 may be provided along the body 126 between the connecting portion 120 and the first ear 122, and one or more second spacers 136 may be provided along the body 126 between the connecting portion 120 and the second ear 124. When included the spacers 134, 136 may provide frictional engagement (e.g., resistance to rotation) between the first hinge portion 112 and the second hinge portion 114.

Optionally, rotation limiters 121 may be provided on the first hinge portion 112 and/or the second hinge portion 114 for limiting a range of movement or rotation of the first hinge portion 112 relative to the second hinge portion 114 (e.g., by engaging each other at a maximum pivot angle). In other embodiments, the rotation limiters 121 may be omitted and/or other types of rotation limiters may be utilized. Optionally, a biasing mechanism may be provided with the hinge 106 such that the hinge is biased towards a particular angular position, although in other embodiments (and as illustrated in FIGS. 4-10) the biasing mechanism may be omitted.

The adjuster 116 of the hinge 106 may adjust resistance to rotation between the first hinge mechanism 112 and the second hinge mechanism 114 by increasing and/or decreasing engagement with the anchoring member 130. As a non-limiting example, the adjuster 116 may increase engagement with the anchoring member 130 by tightening the adjuster 116. Increasing engagement and tightening of the adjuster 116 may cause the ears 122, 124 to provide an increased clamping force on the connecting portion 120, thereby providing increased resistance to rotation and/or a firmer connection between hinge portions 112, 114. Conversely, the adjuster 116 may decrease engagement with the engagement by loosening the adjuster 116. Decreasing engagement and loosening the adjuster 116 may decrease and/or eliminate the clamping force provided by the ears 122, 124 on the connecting portion 120, thereby providing decreased resistance to rotation and/or a looser connecting between hinge portions 112, 114.

The adjuster 116 may provide variable adjustment of the resistance to rotation as desired. As non-limiting examples, the adjuster 116 may adjust the resistance to rotation to provide a firmer connection between the hinge portions 112, 114 after the hinge 106 has become loosened or worn over time. Additionally, or alternatively, the adjuster 116 may adjust the resistance to rotation to provide a desired resistance as set by an operator, passenger, and/or otherwise desired.

The head 128 of the adjuster 116 extending outwards along the pivot axis 118 may allow for adjustment of the hinge 106 without removing any other items of the passenger seat headrest 100. As a non-limiting example, the adjuster 116 may extend outwards from the hinge 106 and downwards such that the head 128 is accessible through an opening or access location that may be already defined on a lower portion of the dress cover 108. The hinges 106 described herein thereby allow for improved access to the hinge 106 and improved adjustment and/or control of the hinge 106, which in turn may increase the service life of the hinge 106 and decreases costs otherwise associated with repairing and/or replacing a hinge. Various other benefits and advantages may be realized with the devices and methods provided herein, and the aforementioned advantages should not be considered limiting.

Different arrangements of the components depicted in the drawings or described above, as well as components and steps not shown or described are possible. Similarly, some features and sub-combinations are useful and may be employed without reference to other features and sub-combinations. Embodiments of the invention have been described for illustrative and not restrictive purposes, and alternative embodiments will become apparent to readers of this patent. Accordingly, the present invention is not limited to the embodiments described above or depicted in the drawings, and various embodiments and modifications may be made insofar as they fall within the scope of the claims below.